Composite board

Abstract

A composite board for use as backerboard for tile, the board including a mesh layer with a mesh fabric, a mat layer with a mat fabric and a polystyrene layer disposed between the two portions where a non-shrinking cement compound saturates and connects the two outer portions with the polystyrene substrate. The composite board's mesh layer incorporates a stretchable mesh which in conjunction with the polystyrene substrate and the non-shrinking cement compound supports standard fasteners used in the home-building industry along with providing a suitable tile adhesion surface. The mat layer incorporates a fiberglass mat which provides high rigidity as well as being suitable for contact with an inner wall or studs. The combination of materials provides a backerboard that is light weight, rigid, economical and easy to build with.

What is claimed:  
     
         1 . A composite board, comprising: 
 an expanded polystyrene planar core having top and bottom planar sides; and    first and second outer reinforcement portions bonded to said top and bottom planar sides of said expanded polystyrene planar core, at least one of said first and second outer reinforcement portions including a woven mesh fabric and a cement compound.    
     
     
         2 . The composite board of  claim 1 , wherein the woven mesh fabric comprises a polypropylene mesh fabric.  
     
     
         3 . The composite board of  claim 2 , wherein the cement compound is non-shrinking.  
     
     
         4 . The composite board of  claim 1 , wherein the woven mesh fabric is saturated with the cement compound.  
     
     
         5 . The composite board of  claim 1 , wherein the woven mesh fabric is formed in a grid-like pattern.  
     
     
         6 . The composite board of  claim 3 , wherein one of the first and second outer reinforcement portions comprises a fiberglass mat fabric with an alkali coating and a non-shrinking cement compound.  
     
     
         7 . The composite board of  claim 1 , wherein the cement compound comprises: 
 approximately 20-35% by weight Portland cement;    approximately 20-35% by weight calcium aluminate cement;    approximately 10-40% by weight silica sand;    approximately 2-6% by weight vinyl acetate-ethylene copolymer;    approximately 0-0.25% cellulose ether;    approximately 0.5 to 1% by weight of a surfactant; and    approximately 10-20% gypsum.    
     
     
         8 . A composite board, comprising: 
 an expanded polystyrene planar core having top and bottom planar sides; and    first and second outer reinforcement portions bonded to said top and bottom planar sides of said expanded polystyrene planar core, at least one of said first and second outer reinforcement portions including a non-woven mat fabric and a cement compound.    
     
     
         9 . The composite board of  claim 8 , wherein the non-woven mat fabric is comprised of a fiberglass mat fabric with an alkali coating.  
     
     
         10 . The composite board of  claim 9 , wherein the cement compound is non-shrinking.  
     
     
         11 . The composite board of  claim 8 , wherein the non-woven mat fabric is saturated with the cement compound.  
     
     
         12 . The composite board of  claim 10 , wherein one of the first and second outer reinforcement portions comprises a polypropylene mesh fabric and a non-shrinking cement compound.  
     
     
         13 . The composite board of  claim 12 , wherein the polypropylene mesh fabric is saturated with the non-shrinking cement compound.  
     
     
         14 . The composite board of  claim 13 , wherein the polypropylene mesh fabric is formed in a grid-like pattern.  
     
     
         15 . The composite board of  claim 8 , wherein the cement compound comprises: 
 approximately 20-35% by weight Portland cement;    approximately 20-35% by weight calcium aluminate cement;    approximately 10-40% by weight silica sand;    approximately 2-6% by weight vinyl acetate-ethylene copolymer;    approximately 0-0.25% cellulose ether;    approximately 0.5 to 1% by weight of a surfactant; and    approximately 10-20% gypsum.    
     
     
         16 . A composite board comprising: 
 a mesh portion;    a mat portion; and    a polystyrene portion disposed between the mesh portion and mat portion.    
     
     
         17 . The composite board of  claim 16 , wherein the mesh portion is comprised of a polypropylene mesh fabric and a cement compound.  
     
     
         18 . The composite board of  claim 17 , wherein the cement compound is non-shrinking.  
     
     
         19 . The composite board of  claim 18 , wherein the polypropylene mesh fabric is saturated with the non-shrinking cement compound.  
     
     
         20 . The composite board of  claim 19 , wherein the polypropylene mesh fabric is formed in a grid-like pattern.  
     
     
         21 . The composite board of  claim 16 , wherein the mat portion is comprised of a fiberglass mat fabric with an acrylic coating and a cement compound.  
     
     
         22 . The composite board of  claim 21 , wherein the cement compound is non-shrinking.  
     
     
         23 . The composite board of  claim 22 , wherein the fiberglass fabric with an acrylic coating is saturated with the non-shrinking cement compound.  
     
     
         24 . The composite board of  claim 16 , wherein the polystyrene portion is comprised of an expanded polystyrene.  
     
     
         25 . The composite board of  claim 17 , wherein the cement compound comprises: 
 approximately 20-35% by weight Portland cement;    approximately 20-35% by weight calcium aluminate cement;    approximately 10-40% by weight silica sand;    approximately 2-6% by weight vinyl acetate-ethylene copolymer;    approximately 0-0.25% cellulose ether;    approximately 0.5 to 1% by weight of a surfactant; and    approximately 10-20% gypsum.    
     
     
         26 . The composite board of  claim 21 , wherein the cement compound comprises: 
 approximately 20-35% by weight Portland cement;    approximately 20-35% by weight calcium aluminate cement;    approximately 10-40% by weight silica sand;    approximately 2-6% by weight vinyl acetate-ethylene copolymer;    approximately 0-0.25% cellulose ether;    approximately 0.5 to 1% by weight of a surfactant; and    approximately 10-20% gypsum.    
     
     
         27 . A three-portioned composite board for use as a tile backerboard, the composite board comprising: 
 a mesh layer comprised of a polypropylene mesh fabric saturated with a non-shrinking cement compound;    a mat layer comprised of a fiberglass mat fabric with an acrylic coating saturated with a non-shrinking cement compound; and    a polystyrene layer comprised of an expanded polystyrene disposed between the mesh layer and the mat layer.    
     
     
         28 . The composite board of  claim 27 , wherein the board has a length of approximately 4 to 12 feet, a width of approximately 3 to 4 feet and a thickness of approximately 6 to 14 mm.  
     
     
         29 . The composite board of  claim 27 , wherein the board weighs approximately 0.5 to 1.0 pounds per square foot.